EP3753670B1 - Method for manufacturing flux-cored wire, flux-cored wire and method for manufacturing welded joint - Google Patents

Method for manufacturing flux-cored wire, flux-cored wire and method for manufacturing welded joint Download PDF

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Publication number
EP3753670B1
EP3753670B1 EP18912463.9A EP18912463A EP3753670B1 EP 3753670 B1 EP3753670 B1 EP 3753670B1 EP 18912463 A EP18912463 A EP 18912463A EP 3753670 B1 EP3753670 B1 EP 3753670B1
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Prior art keywords
flux
content
cored wire
equivalent
oxide
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German (de)
English (en)
French (fr)
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EP3753670A1 (en
EP3753670A4 (en
Inventor
Yuji Hashiba
Naoki Sakabayashi
Rikiya Takayama
Kiyohito Sasaki
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Nippon Steel Corp
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Nippon Steel Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B23K35/0266—Rods, electrodes, wires flux-cored
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3026—Mn as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3073—Fe as the principal constituent with Mn as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/368—Selection of non-metallic compositions of core materials either alone or conjoint with selection of soldering or welding materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding
    • B23K35/404—Coated rods; Coated electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding
    • B23K35/406—Filled tubular wire or rods
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/001—Ferrous alloys, e.g. steel alloys containing N
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/008—Ferrous alloys, e.g. steel alloys containing tin
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/14—Ferrous alloys, e.g. steel alloys containing titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/16—Ferrous alloys, e.g. steel alloys containing copper
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/60—Ferrous alloys, e.g. steel alloys containing lead, selenium, tellurium, or antimony, or more than 0.04% by weight of sulfur

Definitions

  • the present invention relates to a method of manufacturing a flux-cored wire, a flux-cored wire, and a method of manufacturing a welded joint.
  • Anti-weathering steel which is exposed to atmospheric corrosion environments by being used for a long period of time generally has a protective rust layer formed on a surface thereof.
  • the rust layer shields the corrosion-resistant steel from corrosive substances from the outside to inhibit the corrosion of the anti-weathering steel after the formation of the rust layer, and thus the weather resistance of the steel is exhibited.
  • anti-weathering steel is used for structures such as bridges as steel which can be used as a bare material without coating.
  • Patent Document 1 discloses steel for bridges which has excellent weather resistance and coating delamination resistance and can be used as a minimum maintenance material even in a high floating salinity environment such as a seaside area or an area where snow-melting salt is sprayed.
  • Patent Document 2 discloses corrosion-resistant steel for the hold of a coal/ore carrying vessel, which can prolong the life of a coating film and inhibit the corrosion after delamination even in a corrosion environment in which the coating film is easily damaged mechanically and easily affected by both SO 4 2- and Cl - .
  • the excess weld metal has a problem in weather resistance and coating corrosion resistance in a welded joint.
  • the excess weld metal is the outermost layer of the weld metal, and while the welded joint is used, the coating film applied to the area of the excess weld metal is relatively more likely to receive severe collision and mechanical friction with other objects than a surface of the coating film applied to the surrounding smooth parent material.
  • the coating film of the excess weld metal tends to be thinner than the coating film of the surrounding parent material in the coating process.
  • the coating film easily peels off from the surface of the excess weld metal, and thus the surface of the excess weld metal is likely to become the starting point of corrosion in which the coating film destruction progressively progresses at an early stage from the start of use of the steel structure.
  • Patent Document 3 proposes a wire for gas shield arc welding which is suitable for welding of high Ni-based highly anti-weathering steel, enables good welding workability, particularly good slag delamination, and imparts corrosion resistance to sea salt to a weld metal without deteriorating the corrosion resistance of a parent material.
  • it is difficult to obtain the effect of prolonging the coating life of a structure including the weld metal.
  • Patent Documents 4, 5, and 6 propose a flux-cored wire for gas shield arc welding having excellent corrosion resistance.
  • An object of the invention is to provide a method of manufacturing a flux-cored wire which can provide a weld metal which has excellent mechanical properties and is excellent in welding workability, weldability, weather resistance of a weld part, and coating corrosion resistance even in a case where horizontal fillet welding is performed on bridges, harbor structures, or corrosion-resistant steel which is used in a high floating salinity environment such as a seaside area, a flux-cored wire, and a method of manufacturing a welded joint.
  • excellent welding workability means that the amount of spatters is small, and the bead shape, the bead appearance, and the slag delamination are excellent.
  • excellent weldability means that no pits are formed and hot cracking does not occur.
  • Excellent mechanical properties mean that the tensile strength and the toughness are excellent.
  • a flux-cored wire which is obtained by a method of manufacturing a flux-cored wire of the invention and a welded joint formed of the flux-cored wire, it is possible to obtain a weld metal which has excellent mechanical properties and is excellent in welding workability, weldability, weather resistance of a weld part, and coating corrosion resistance even in a case where horizontal fillet welding is performed on bridges, harbor structures, or corrosion-resistant steel which is used in a high floating salinity environment such as a seaside area.
  • wire various flux-cored wires (hereinafter, may be abbreviated as "wire"), and examined details thereof.
  • the inventors investigated the influence of the chemical composition (hereinafter, may be referred to as "components") in the wire on the corrosion resistance in a corrosion environment with a large amount of dispersed salt.
  • components the chemical composition in the wire
  • the corrosion resistance in a corrosion environment with a large amount of dispersed salt can be improved by adding Cu and Sn as chemical components of the flux-cored wire.
  • the inventors have found that the bead shape and the bead appearance are improved by adjusting the Ti oxide content, the Si oxide content, the Zr oxide content, the Al content, the Fe oxide content, the Al oxide content, and the fluorine compound content in the wire, and the slag delamination is improved by adjusting the Si oxide content, the Zr oxide content, the Al content, the Fe oxide content, and the total amount of a Na compound and a K compound.
  • the inventors have also found that the pit resistance and reducing the amount of spatters are improved by adjusting the Ti oxide content, the Si oxide content, and the Mg content in the wire, and the mechanical properties are improved by adjusting the C content, the Si content, and the Mn content in the wire.
  • the inventors have found that it is also required to consider the interaction between the above-described elements in order to improve the corrosion resistance of a weld metal in a corrosion environment with a large amount of dispersed salt. Specifically, the inventors have found that in a case where the ratio between the content ratio of Sn (and Sb) and Mo and W as alloy compositions is not within a predetermined range, especially in a high floating salinity environment, it is difficult to prevent the corrosion depth immediately under a coating film damage portion from being increased in a case where coating film damages are generated by the above-described deterioration in the coating film, and the coating delamination resistance is lowered.
  • FIG. 4 is a cross-sectional view of a flux-cored wire 10 in a manufacturing stage
  • FIG. 5 is a cross-sectional view of a flux-cored wire 10 manufactured by caulking.
  • the method of manufacturing a flux-cored wire 10 according to this embodiment in which the inside of a steel sheath 11 is filled with a flux 12 includes a step of filling the inside of a steel sheet 13 with the flux 12 while forming the steel sheet into a round shape (see FIG.
  • Means for joining is not particularly limited, and examples thereof include caulking and welding.
  • a wire 10 manufactured by caulking shown in FIG. 5 has a seam 14.
  • a flux-cored wire 10 manufactured by welding shown in FIG. 6 is a so-called seamless wire having a weld part 15 without the seam 14.
  • the seamless wire is preferable since it can be further heat-treated to reduce the amount of hydrogen in the wire.
  • the moisture-absorption amount after the manufacturing is small, the amount of diffusible hydrogen of a weld metal can be reduced and the crack resistance can be improved.
  • FIG. 6 is a cross-sectional view of a flux-cored wire 10 manufactured by welding.
  • the method of manufacturing a flux-cored wire 10 may further include a step of plating an outer surface of the steel sheath 11 and/or a step of applying a lubricant to the outer surface of the steel sheath 11.
  • the plating is, for example, copper plating.
  • the lubricant is, for example, vegetable oil or PTFE oil.
  • the chemical compositions of the steel sheath 11 and the flux 12 are controlled within a predetermined range.
  • the components contained in the steel sheath 11 and the flux 12 melt during welding to form a weld metal, and a part thereof is oxidized and discharged as slag to the outside of the weld metal. Therefore, the components to be described below are thought to provide the same effect even in a case where the components are contained in any of the steel sheath 11 and the flux 12. For the above reason, it is not necessary to distinguish the chemical composition of the steel sheath 11 from the chemical composition of the flux 12 in the manufacturing method according to this embodiment.
  • a chemical composition (component) existing in the form of oxide or fluoride will be defined as a slag composition
  • a chemical composition (component) existing as another single metal or alloy will be defined as an alloy composition
  • C, P, and S are not metal elements. However, for the sake of convenience, these are included as alloy compositions in this embodiment.
  • oxides thereof are considered to exhibit the same action as that of Al and Bi as alloy compositions, and thus the oxides are substantially handled as alloy compositions.
  • the amount of an element to be described below is the amount of an element existing as an alloy composition as long as there is no particular specification such as the fact that the element is a slag composition.
  • the alloy composition may be contained in any of the steel sheath 11 and the flux 12, but the slag composition is usually contained only in the flux 12.
  • the diameter and the filling rate (the ratio of the mass of the flux 12 to the total mass of the flux-cored wire 10) of the flux-cored wire 10 to be manufactured and the design values (target values) of the chemical composition of the flux-cored wire 10 are previously determined.
  • the steel sheet 13 which is a raw material of the steel sheath a material having a specific chemical composition is usually used. From documents showing the chemical composition (for example, the result of analysis of the chemical composition of the steel sheet 13, or an inspection certificate or catalog of a steel manufacturer), the chemical composition of the steel sheath 11 can be grasped.
  • raw materials of the flux 12 are selected from documents (for example, a report, certificate, or catalog of a raw material manufacturer) showing the chemical compositions of the raw materials of the flux 12 (both the raw materials of the slag compositions and the raw materials of the metal components), and the mixing ratio of the raw materials is determined.
  • the raw materials of the flux 12 selected according to the above procedure are mixed with the mixing ratio determined according to the above procedure to produce the flux 12.
  • a flux-cored wire 10 having a designed chemical composition can be manufactured.
  • the flux-cored wire 10 is plated, it is necessary to control the chemical compositions of the steel sheath 11 and the flux 12 according to the chemical composition and the thickness of the plating.
  • the unit "%" for the chemical composition represents the mass% with respect to the total mass of the flux-cored wire 10 (total mass of the steel sheath 11 and the flux 12) unless otherwise specified.
  • the total mass of the flux-cored wire 10 is the total mass of the steel sheath 11 and the flux 12, and in a case where the surface of the steel sheath 11 is plated, the mass of the plating is included in the mass of the steel sheath 11.
  • the mass of a lubricant applied to the outer surface of the steel sheath 11 is not included in the total mass of the flux-cored wire 10.
  • C is an element which is contained in the wire to obtain the strength and toughness of a weld metal required for a welded structure.
  • C is a component contained in the steel sheath 11, and may be in a metal powder contained in a small amount in an iron alloy such as Fe-Si, Fe-Mn, and Fe-Si-Mn in the flux 12.
  • the C content is less than 0.03%, the strength and toughness of the weld metal are decreased.
  • the toughness of the weld metal is decreased with an increase in the strength of the weld metal. Accordingly, the C content is set to 0.03% to 0.10%.
  • the lower limit of the C content is preferably 0.04% or 0.05%.
  • the upper limit of the C content is preferably 0.09% or 0.08%.
  • C may exist as a component of the steel sheath 11 and as a component of a metal powder and an alloy powder in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described C content by controlling the C content of the steel sheath 11 and the C content of the flux 12.
  • Si is an element acting as a deoxidizing agent and contained to secure the strength and toughness of a weld metal.
  • Si is a component contained in the steel sheath 11, and may be as a metal Si and in Fe-Si, Fe-Si-Mn, and the like in the flux 12.
  • the Si content is less than 0.40%, pits are generated due to insufficient deoxidation.
  • the Si content is less than 0.40%, the strength and toughness of a weld metal are decreased.
  • the Si content exceeds 0.85%, the strength of the weld metal is increased, and thus the toughness of the weld metal is decreased. Accordingly, the Si content is set to 0.40% to 0.85%.
  • the lower limit of the Si content is preferably 0.55% or 0.65%.
  • the upper limit of the Si content is preferably 0.75% or 0.70%.
  • Si may exist as a component of the steel sheath 11 and as a metal Si and a component of an alloy powder such as Fe-Si and Fe-Si-Mn in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Si content by controlling the Si content of the steel sheath 11 and the Si content of the flux 12.
  • Mn is an element acting as a deoxidizing agent and contained in the wire to secure the strength and toughness of a weld metal.
  • the Mn content is less than 1.5%, pits are generated due to insufficient deoxidation.
  • the Mn content is less than 1.5%, the strength and toughness of the weld metal are decreased.
  • the Mn content exceeds 3.5%, the strength of the weld metal is increased, and thus the toughness of the weld metal is decreased. Accordingly, the Mn content is set to 1.5% to 3.5%.
  • the lower limit of the Mn content is preferably 2.4% or 2.6%.
  • the upper limit of the Mn content is preferably 3.0% or 2.8%.
  • Mn may exist as a component of the steel sheath 11 and as a metal Mn and a component of an alloy powder such as Fe-Mn and Fe-Si-Mn in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Mn content by controlling the Mn content of the steel sheath 11 and the Mn content of the flux 12.
  • P and S are elements which may adversely affect the mechanical characteristics of a weld metal and impair the corrosion resistance of the weld metal, it is most preferable that P and S are not contained in the wire. Therefore, the lower limits of the P content and the S content are 0%. However, P and S may be contained within a range not impairing the characteristics of the weld metal since a lot of costs are required to completely remove P and S from the material of the wire. In the flux-cored wire 10 according to this embodiment, 0.020% or less of P and 0.020% or less of S are allowed.
  • the upper limit of the P content or the S content may be 0.015%, 0.010%, or 0.005%.
  • the lower limit of the P content or the S content may be 0.001%, 0.002%, or 0.005%.
  • Cu is an element acting to improve the corrosion resistance of a weld metal.
  • the Cu content is less than 0.03%, the corrosion resistance of the weld metal is deteriorated.
  • the Cu content exceeds 0.70%, the effect of improving the corrosion resistance of the weld metal is saturated.
  • the Cu content exceeds 0.70%, the toughness of the weld metal is decreased. Accordingly, the Cu content is set to 0.03% to 0.70%.
  • the lower limit of the Cu content is preferably 0.05%, 0.15%, 0.17%, or 0.20%.
  • the upper limit of the Cu content is preferably 0.35%, 0.32%, or 0.30%.
  • Cu improves the weather resistance and coating delamination resistance of a weld metal
  • Cu reduces the rate of a dissolution reaction (corrosion reaction) of a Cu-containing weld metal itself, and in the Cu-containing weld metal, a corrosion product (rust) formed on a surface (such as an excess weld metal portion) has a characteristic fine and dense structure, and thus forms a highly corrosion-resistant rust layer inhibiting permeation of water, oxygen, chloride ions, and the like.
  • Cu may exist as a component of the steel sheath 11 itself, a plating component of the steel sheath 11, or a metal Cu in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Cu content by controlling the Cu content of the steel sheath 11, the Cu content of the plating, and the Cu content of the flux 12.
  • Sn is an element having an effect of improving the corrosion resistance of a weld metal.
  • the corrosion resistance is deteriorated.
  • the Sn content exceeds 0.30%, hot cracking easily occurs. Accordingly, the Sn content is set to 0.05% to 0.30%.
  • the lower limit of the Sn content is preferably 0.10% or 0.12%.
  • the upper limit of the Sn content is preferably 0.25%, 0.20%, or 0.18%.
  • Sn may be contained as a component of the steel sheath 11 or as a metal Sn or a Sn compound in the flux 12. It is possible to manufacture a flux-cored wire 10 having the above-described Sn content primarily by controlling the Sn content of the steel sheath 11 and the Sn content of the flux 12.
  • the reason why Sn improves the weather resistance and coating delamination resistance of a weld metal is that the metal Sn in the weld metal is eluted as a tin ion (II) (Sn 2+ ) and exhibits an inhibiting action in a portion exposed to the environment, that is, in an acidic chloride solution to inhibit the corrosion in an anode in which the pH decreases.
  • the metal Sn in the weld metal also acts to reduce an iron (III) ion (Fe 3+ ) (2Fe 3+ +Sn 2+ ⁇ 2Fe 2+ +Sn 4+ ), the corrosion promoting action of Fe 3+ is inhibited, and the weather resistance in a high floating salinity environment is improved.
  • Mg is an element which acts as a strong deoxidizing agent, and thus has an effect of preventing the generation of pits.
  • the Mg content is less than 0.05%, the effect of Mg as a deoxidizing agent is not exhibited, and pits are generated.
  • the Mg content exceeds 0.50%, the amount of spatters is increased due to a rough arc. Accordingly, the Mg content is set to 0.05% to 0.50%.
  • the lower limit of the Mg content is preferably 0.15%, 0.18%, or 0.20%.
  • the upper limit of the Mg content is preferably 0.35%, 0.30%, or 0.25%.
  • a general Mg content of the steel sheath 11 is almost 0%.
  • Mg often exists in the wire as a metal Mg or an alloy powder such as Al-Mg in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Mg content primarily by controlling the Mg content of the flux 12.
  • Al is an element which acts as a deoxidizing agent and acts to increase the viscosity of slag by existing as an Al oxide in the molten slag to thus suppress retreat of the molten pool during horizontal fillet welding, thereby maintaining sufficient slag enclosing properties.
  • the Al content is less than 0.05%, the bead has a convex shape, and thus undercut occurs in the upper leg portion.
  • the Al content exceeds 0.50%, the bead shape loses smoothness, and thus the bead has a swelling toe portion.
  • the Al content is set to 0.05% to 0.50%.
  • the lower limit of the Al content is preferably 0.07%, 0.10%, or 0.15%.
  • the upper limit of the Al content is preferably 0.25% or 0.20%.
  • Al may exist as a component of the steel sheath 11 or as a metal Al powder, an Fe-Al alloy powder, an Al-Mg alloy powder, or the like in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Al content and the above-described Al oxide content by primarily controlling the Al content of the steel sheath 11 and the Al content of the flux 12. In order to adjust the Al content of the flux-cored wire 10 within the above-described ranges, a steel sheath 11 having the above-described Al content and a flux 12 having the above-described Al content may be used.
  • Ti Oxide 1.50% to Less Than 4.60% in terms of TiO 2 Equivalent
  • a Ti oxide which is a slag composition acts to uniformly enclose the entire bead by slag.
  • the Ti oxide has an effect of stably sustaining an arc, thereby reducing the amount of spatters.
  • the TiO 2 equivalent of the Ti oxide is less than 1.50%, the amount of slag generated is not sufficient, and thus the bead cannot be uniformly enclosed. Accordingly, the bead appearance is deteriorated due to seizure of the slag on the bead surface.
  • the TiO 2 equivalent of the Ti oxide is less than 1.50%, the arc stabilization effect is not exhibited, and thus the amount of spatters is increased.
  • the TiO 2 equivalent of the Ti oxide is 4.60% or more, the arc is stabilized, and the amount of spatters thus is decreased.
  • the viscosity of the slag is increased, and thus the slag becomes thick, and the bead has a swelling toe portion.
  • the TiO 2 equivalent of the Ti oxide is set to 1.50% to less than 4.60%.
  • the lower limit of the TiO 2 equivalent of the Ti oxide is preferably 2.50%, 2.80%, or 3.00%.
  • the upper limit of the TiO 2 equivalent of the Ti oxide is preferably 4.30%, 4.00%, 3.70%, or 3.50%.
  • the Ti oxide may primarily exist as rutile, titanium oxide, titanium slag, iluminite, sodium titanate, potassium titanate, or the like in the flux 12. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described Ti oxide content primarily by controlling the Ti oxide content of the flux 12.
  • the TiO 2 equivalent of the Ti oxide is the mass% of TiO 2 with respect to the total mass of the wire in a case where all the Ti oxides (for example, TiO 2 , Ti 2 O 3 , Ti 3 O 5 , sodium titanate, and potassium titanate) contained in the wire are regarded as TiO 2 . Accordingly, the TiO 2 equivalent is obtained by measuring the total mass of only Ti, obtained by excluding O from the mass of the Ti oxide, and substituting the total Ti content into the following Expression.
  • TiO 2 Equivalent Mass% of Ti Which Forms Ti Oxide With respect to Total Mass of Wire ⁇ Expression Weight of TiO 2 / Atomic Weight of Ti
  • the SiO 2 equivalent of a Si oxide, the ZrO 2 equivalent of a Zr oxide, the FeO equivalent of a Fe oxide, and the Al 2 O 3 equivalent of an Al oxide can also be obtained by the same calculation.
  • Si Oxide 0.30% to 1.00% in terms of SiO 2 Equivalent
  • a Si oxide which is a slag composition acts to increase the viscosity of molten slag, thereby improving slag delamination.
  • the SiO 2 equivalent of the Si oxide is less than 0.30%, the slag delamination is deteriorated due to a poor slag enclosing state, and the bead shape and the bead appearance are also deteriorated.
  • the SiO 2 equivalent of the Si oxide exceeds 1.00%, the amount of spatters is increased.
  • pits and gas grooves are easily generated.
  • the SiO 2 equivalent of the Si oxide is set to 0.30% to 1.00%.
  • the lower limit of the SiO 2 equivalent of the Si oxide is preferably 0.50% or 0.60%.
  • the upper limit of the SiO 2 equivalent of the Si oxide is preferably 0.90% or 0.80%.
  • the Si oxide may primarily exist as silica sand, zircon sand, feldspar, sodium silicate, potassium silicate, or the like in the flux 12. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described Si oxide content (0.30% to 1.00% in terms of SiO 2 equivalent) primarily by controlling the Si oxide content of the flux 12.
  • a Zr oxide which is a slag composition acts to increase slag enclosing properties in horizontal fillet welding, thereby forming a smooth bead shape.
  • the ZrO 2 equivalent of the Zr oxide is less than 0.10%, the bead shape is rough, and a convex bead shape is obtained. Thus, the slag delamination is deteriorated.
  • the ZrO 2 equivalent of the Zr oxide exceeds 0.50%, the bead is likely to have a convex shape. Accordingly, the ZrO 2 equivalent of the Zr oxide is set to 0.10% to 0.50%.
  • the lower limit of the ZrO 2 equivalent of the Zr oxide is preferably 0.15% or 0.20%.
  • the upper limit of the ZrO 2 equivalent of the Zr oxide is preferably 0.40% or 0.30%.
  • the Zr oxide may primarily exist as zircon sand, zirconium oxide, or the like in the flux 12. In some cases, the Zr oxide may be contained in a small amount in the above-described Ti oxide. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described Zr oxide content (0.10% to 0.50% in terms of ZrO 2 equivalent) primarily by controlling the Zr oxide content of the flux 12.
  • a Fe Oxide such as FeO and Fe 2 O 3 acts to adjust the viscosity and solidification temperature of molten slag and to eliminate the swelling of a bead toe portion, thereby improving conformability with a lower plate.
  • the FeO equivalent of the Fe oxide is less than 0.10%, the bead toe portion swells, and thus the shape of the bead toe portion is deteriorated.
  • the FeO equivalent of the Fe oxide exceeds 1.00%, the slag enclosing state is deteriorated, and thus the slag delamination is deteriorated and the bead toe portion swells.
  • the FeO equivalent of the Fe oxide is set to 0.10% to 1.00%.
  • the lower limit of the FeO equivalent of the Fe oxide is preferably 0.20%, 0.30%, or 0.40%.
  • the upper limit of the FeO equivalent of the Fe oxide is preferably 0.80%, 0.70%, or 0.60%.
  • the Fe oxide exists primarily in the flux 12 in many cases, and it is possible to manufacture a flux-cored wire 10 having the above-described Fe oxide content (0.10% to 1.00% in terms of FeO equivalent) primarily by controlling the Fe oxide content of the flux 12.
  • an Al oxide in a case where an Al oxide constitutes molten slag, it acts to improve the slag enclosing properties, thereby preventing undercut on the upper leg side of a fillet bead.
  • the Al 2 O 3 equivalent of the Al oxide is less than 0.05%, undercut easily occurs on the upper leg side of the fillet bead.
  • the Al 2 O 3 equivalent of the Al oxide exceeds 0.50%, a bead shape in which a bead toe portion on the lower leg side of the fillet bead swells is obtained. Accordingly, the Al 2 O 3 equivalent of the Al oxide is set to 0.05% to 0.50%.
  • the lower limit of the Al 2 O 3 equivalent of the Al oxide is preferably 0.10%, 0.15%, or 0.20%.
  • the upper limit of the Al 2 O 3 equivalent of the Al oxide is preferably 0.35%, 0.30%, or 0.25%.
  • the Al oxide exists primarily as a component such as alumina or feldspar in the flux 12. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described Al oxide content (0.05% to 0.50% in terms of Al 2 O 3 equivalent) primarily by controlling the Al oxide content of the flux 12.
  • Total of Na Compound and K Compound 0.050% to 0.200% in terms of Sum of Na 2 O Equivalent and K 2 O Equivalent
  • a Na compound and a K compound not only act as an arc stabilizer, but also act as a slag forming agent to suppress a rapid increase in the viscosity of molten slag during solidification to thus increase the pit resistance, thereby forming a smooth bead shape.
  • the Na compound and the K compound may exist as solid components of liquid glass formed of sodium silicate, potassium silicate, and the like in the flux, or fluorine compounds such as sodium fluoride and potassium silicofluoride.
  • the sum of the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound is less than 0.050%, a large amount of spatters having a large diameter is generated, pits and gas grooves are also easily generated, the bead has a rough surface, and the bead shape and the bead appearance are deteriorated.
  • the sum of the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound exceeds 0.200%, the slag delamination, the bead shape, and the bead appearance are deteriorated, and thus the amount of spatters are also increased.
  • the sum of the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound is set to 0.050% to 0.200%.
  • the lower limit of the sum of the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound is preferably 0.080% or 0.100%.
  • the upper limit of the sum of the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound is preferably 0.150% or 0.120%.
  • the content of the Na compound and the K compound in the steel sheath 11 is substantially 0%. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described content of the Na compound and the K compound (0.050% to 0.200% in terms of sum of Na 2 O equivalent and K 2 O equivalent) primarily by controlling the content of the Na compound and the K compound in the flux 12.
  • the Na 2 O equivalent of the Na compound is the mass% of Na 2 O with respect to the total mass of the wire in a case where all the Na compounds contained in the wire are regarded as Na 2 O.
  • the K 2 O equivalent of the K compound is the mass% of K 2 O with respect to the total mass of the wire in a case where all the K compounds contained in the wire are regarded as K 2 O.
  • the Na 2 O equivalent of the Na compound and the K 2 O equivalent of the K compound are calculated by the same means as in the case of the TiO 2 equivalent of the Ti oxide described above.
  • a fluorine compound which is a slag composition acts to increase the directivity of an arc, thereby forming a stable molten pool.
  • the fluorine compound acts to adjust the viscosity of slag, thereby forming a smooth bead shape, and also acts to improve the pit resistance.
  • the fluorine compound may exist as magnesium fluoride, cryolite, sodium fluoride, potassium silicofluoride, or the like in the flux 12.
  • the fluorine compound content of the steel sheath 11 is substantially 0%. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described fluorine compound content (0.02% to 0.20% in terms of F equivalent) primarily by controlling the fluorine compound content of the flux 12.
  • the F equivalent of the fluorine compound is set to 0.02% to 0.20%.
  • the lower limit of the F equivalent of the fluorine compound is preferably 0.03% or 0.05%.
  • the upper limit of the F equivalent of the fluorine compound is preferably 0.15%, 0.10%, or 0.07%.
  • the F equivalent of the fluorine compound is, by mass% with respect to the total mass of the wire, the total amount of F contained in all the fluorine compounds in the wire.
  • the steel sheath 11 and the flux 12 contain the above elements and compounds as essential requirements, but may further optionally contain the following elements and compounds.
  • the method of manufacturing a flux-cored wire 10 according to this embodiment can solve the problems, and thus the lower limit of the amount of each of the optional components is 0%.
  • Bi acts to improve the slag delamination, put a gloss on a bead surface, and improve the bead appearance, and thus may be contained in the wire 10.
  • Bi may exist as a component in the steel sheath and as a metal Bi, oxidized Bi, and the like in the flux 12.
  • the total Bi equivalent of Bi and the Bi oxide exceeds 0.035%, the slag at the top of the bead flows, the entire bead surface cannot be enclosed by the slag, and thus the bead appearance is deteriorated. Accordingly, the total Bi equivalent of the metal Bi and the Bi oxide in the flux 12 is set to 0.035% or less.
  • the upper limit of the total Bi equivalent of the metal Bi and the Bi oxide is preferably 0.030% or 0.025%.
  • the lower limit of the total Bi equivalent of the metal Bi and the Bi oxide is preferably 0.005%, 0.010%, or 0.015%.
  • a steel sheet 13 containing Bi is very expensive. Therefore, it is possible to manufacture a flux-cored wire 10 having the above-described Bi content and Bi oxide content primarily by controlling the Bi content and the Bi oxide content of the flux 12.
  • a steel sheath 11 having the above-described chemical composition (Bi and Bi oxide: 0% to 0.035% in total in terms of Bi equivalent) and a flux 12 having the above-described chemical composition (Bi and Bi oxide: 0% to 0.035% in total in terms of total Bi equivalent) may be used.
  • the Bi equivalent is the sum of the mass% of Bi existing as a metal or an alloy with respect to the total mass of the wire and the mass% of Bi in the Bi oxide (for example, Bi 2 O 3 ) with respect to the total mass of the wire. Since Bi existing as a metal or an alloy and the Bi oxide provide the same effect, both the amount of Bi existing as a metal or an alloy and the Bi oxide content are controlled as a Bi equivalent in the method of manufacturing a flux-cored wire 10 according to this embodiment.
  • Ni, Ti, and B may be contained in the wire 10 to secure the toughness of a weld metal at low temperatures.
  • the Ni content exceeds 2.50%, hot cracking easily occurs. Accordingly, the Ni content is set to 2.50% or less.
  • the upper limit of the Ni content is preferably 2.30%, 2.00%, or 1.50%.
  • the lower limit of the Ni content is preferably 0.10% or 0.20%.
  • the Ti content exceeds 0.30%, slag is seized on the bead surface, the bead appearance is deteriorated, and the amount of spatters is also increased. In a case where the Ti content exceeds 0.30%, the toughness of a weld metal is also decreased. In addition, in a case where the B content exceeds 0.010%, hot cracking easily occurs. Accordingly, the Ti content is set to 0.30% or less, and the B content is set to 0.010% or less.
  • the upper limit of the Ti content is preferably 0.25% or 0.20%.
  • the upper limit of the B content is preferably 0.008% or 0.005%.
  • Ni may be contained as a component of the steel sheath 11, and as a metal Ni and in Fe-Ni and the like in the flux 12.
  • Ti and B may be contained in the wire 10 to secure the toughness of a weld metal at low temperatures.
  • Ti may exist as a component of the steel shell 11 and as a metal Ti and a component of Fe-Ti in the flux 12.
  • B may exist as a component of the steel sheath 11 and as a component of Fe-B or Fe-Mn-B in the flux 12.
  • a flux-cored wire 10 having the above-described Ni content, Ti content, and B content primarily by controlling the Ni content, the Ti content, and the B content of the steel sheath 11 and the Ni content, the Ti content, and the B content of the flux 12.
  • a steel sheath 11 having the above-described chemical composition Ni: 0% to 2.50%, Ti: 0% to 0.30%, B: 0% to 0.010%) and a flux 12 having the above-described chemical composition (Ni: 0% to 2.50%, Ti: 0% to 0.30%, B: 0% to 0.010%) may be used.
  • one or more selected from the group consisting of 0.10% or more of Ni, 0.03% or more of Ti, and 0.002% or more of B are preferably contained in the wire 10.
  • Ni 0.10% to 2.50%
  • Ti 0.03% to 0.30%
  • B 0.002% to 0.010%.
  • Mo has an effect of improving the strength of a weld metal, and thus may be contained in the wire 10.
  • the Mo content exceeds 0.400%, it is impossible to prevent the average corrosion depth immediately under a coating film damage portion from being increased due to competition with Sn ionization especially in a case where coating film damages are generated in a high floating salinity environment.
  • the upper limit of the Mo content is preferably 0.400%.
  • the lower limit of the Mo content is preferably 0.010%.
  • the upper limit of the Mo content is preferably 0.300%, 0.100%, or 0.040%.
  • Mo may exist in the wire 10 as a component of the steel sheath 11 and as a metal Mo and an alloy powder such as Fe-Mo in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Mo content primarily by controlling the Mo content of the steel sheath 11 and the Mo content of the flux 12. In order to adjust the Mo content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described Mo content (that is, 0% to 0.400%) and a flux 12 having the above-described Mo content (that is, 0% to 0.400%) may be used.
  • the W may be contained in the wire 10 since it contributes to the improvement of the strength of a weld metal.
  • the W content exceeds 0.200%, it is impossible to prevent the average corrosion depth immediately under a coating film damage portion from being increased due to competition with Sn ionization especially in a case where coating film damages are generated in a high floating salinity environment.
  • the upper limit of the W content is set to 0.200%.
  • the upper limit of the W content is preferably 0.150%, 0.100%, or 0.010%.
  • W may exist in the wire 10 as a component of the steel sheath 11 or as an alloy powder of a metal W or the like in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described W content primarily by controlling the W content of the steel sheath 11 and the W content of the flux 12. In order to adjust the W content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described W content (that is, 0% to 0.200%) and a flux 12 having the above-described W content (that is, 0% to 0.200%) may be used.
  • the Cr may be contained in the wire since it contributes to the improvement of the strength of a weld metal.
  • the Cr content exceeds 0.500%, it is impossible to prevent the corrosion depth immediately under a coating film damage portion from being increased due to competition with Sn ionization especially in a case where coating film damages are generated in a high floating salinity environment.
  • the upper limit of the Cr content is preferably 0.500%.
  • the upper limit of the Cr content is preferably 0.100% or 0.050%.
  • Cr may exist in the wire as a component of the steel sheath 11, or as a metal Cr or an alloy powder such as Fe-Cr in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Cr content primarily by controlling the Cr content of the steel sheath 11 and the Cr content of the flux 12. In order to adjust the Cr content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described Cr content (that is, 0% to 0.500%) and a flux 12 having the above-described Cr content (that is, 0% to 0.500%) may be used.
  • Nb may be contained in the wire 10 since it contributes to the improvement of the strength of a weld metal by precipitation strengthening.
  • the Nb content exceeds 0.300%, Nb forms coarse precipitates and reduces the toughness of the weld metal.
  • the upper limit of the Nb content is set to 0.300%.
  • the upper limit of the Nb content may be 0.250% or 0.200%.
  • the lower limit of the Nb content may be 0.050% or 0.100%.
  • Nb may exist in the wire 10 as a component of the steel sheath 11, a metal Nb or an alloy powder such as Fe-Nb in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Nb content primarily by controlling the Nb content of the steel sheath 11 and the Nb content of the flux 12. In order to adjust the Nb content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described Nb content (that is, 0% to 0.300%) and a flux 12 having the above-described Nb content (that is, 0% to 0.300%) may be used.
  • V may be contained in the wire 10 since it contributes to the improvement of the strength of a weld metal.
  • the V content exceeds 0.300%, the strength of the weld metal is excessively increased, and thus the toughness of the weld metal is decreased. Accordingly, the V content is set to 0.300% or less.
  • the V content is preferably 0.010% or more.
  • the upper limit of the V content is preferably 0.200% or 0.100%.
  • V may exist in the wire 10 as a component of the steel sheath 11, a metal V or an alloy powder such as Fe-V in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described V content primarily by controlling the V content of the steel sheath 11 and the V content of the flux 12. In order to adjust the V content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described V content (that is, 0% to 0.300%) and a flux 12 having the above-described V content (that is, 0% to 0.300%) may be used.
  • N is an element which impairs the toughness and the like of a weld metal, and thus it is most preferable that N is not contained in the wire 10. Therefore, the lower limit of the N content is 0%. However, N may be contained within a range not impairing the properties of the weld metal since a lot of costs are required to completely remove N from the material of the wire. In the flux-cored wire 10 according to this embodiment, 0.0080% or less of N is allowed. The upper limit of the N content may be 0.0070%, 0.0060%, or 0.0050%.
  • a steel sheath 11 having the above-described N content (that is, 0% to 0.0080%) and a flux 12 having the above-described N content (that is, 0% to 0.0080%) may be used.
  • Ca and REM have an effect of improving the ductility and toughness of a weld metal by changing forms of a sulfide and an oxide.
  • the Ca content may be 0.0002% or more, and the REM content may be 0.0002% or more.
  • Ca and REM are also elements which increase the amount of spatters, thereby impairing weldability. Accordingly, the upper limit of the Ca content is 0.0050%, and the upper limit of the REM content is 0.0050%.
  • the upper limit of the Ca content may be 0.0040% or 0.0030%.
  • the upper limit of the REM content may be 0.0040% or 0.0030%.
  • Ca and REM may exist in the wire 10 as a component of the steel sheath 11, or as a Ca compound or a REM compound in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Ca content and REM content primarily by controlling the Ca content and the REM content of the steel sheath 11 and the Ca content and the REM content of the flux 12.
  • a steel sheath 11 having the above-described Ca content (that is, 0% to 0.0050%) and REM content (that is, 0% to 0.0050%) and a flux 12 having the above-described Ca content (that is, 0% to 0.0050%) and REM content (that is, 0% to 0.0050%) may be used.
  • Sb is an element which imparts weather resistance and coating delamination resistance to a weld metal as in the case of Sn. Accordingly, the Sb content may be 0.0010% or 0.0020%. However, in a case where the Sb content exceeds 0.0050%, the toughness of the weld metal is decreased due to the segregation of Sb at the grain boundary of the weld metal. Accordingly, the upper limit of the Sb content is 0.0050%. The upper limit of the Sb content may be 0.0040% or 0.0030%.
  • Sb may exist in the wire 10 as a component of the steel sheath 11, or as a metal Sb or an alloy powder such as a Sb compound in the flux 12. That is, it is possible to manufacture a flux-cored wire 10 having the above-described Sb content primarily by controlling the Sb content of the steel sheath 11 and the Sb content of the flux 12. In order to adjust the Sb content of the flux-cored wire 10 within the above-described range, a steel sheath 11 having the above-described Sb content (that is, 0% to 0.0050%) and a flux 12 having the above-described Sb content (that is, 0% to 0.0050%) may be used.
  • the total amounts of Sn and Sb is required to exceed the total amounts of Mo and W. This is because in a case where the total amounts of Sn and Sb is equal to or less than the total amounts of Mo and W, especially in a high floating salinity environment, it is difficult to prevent the average corrosion depth immediately under a coating film damage portion from being increased in a case where coating film damages are generated by deterioration in the coating film, and the coating delamination resistance is decreased.
  • an index X obtained by substituting the Sn content, the Sb content, the Mo content, and the W content into the following Expression is more than 0.
  • the components of the flux-cored wire 10 are preferably controlled such that the index X is 0.05 or more, 0.08 or more, or 0.10 or more.
  • Index X Sn + Sb ⁇ Mo + W
  • the remainder of the chemical composition of the wire 10 consists of Fe and impurities.
  • Fe exists as a component of the steel sheath 11 and a component in the flux 12 (Fe powder, Fe alloy powder (for example, Fe-Mn alloy powder, Fe-Si alloy powder, and the like)).
  • a Fe powder is used to adjust components other than Fe, and the content thereof may be optionally adjusted to 0% with respect to the total mass of the wire.
  • the upper limit of the Fe powder content may be 10.0% or less with respect to the total mass of the wire.
  • the impurities refer to raw materials such as ore or scrap in industrial manufacturing of the wire, or components mixed by various factors in the manufacturing steps, and mean those which are acceptable within a range not adversely affecting the method of manufacturing a wire according to this embodiment.
  • the wire according to this embodiment may contain O as impurities other than O of the oxides, and such O is acceptable as long as the content thereof is 0% to 0.080%.
  • the total amount of O, including O of the Ti oxide, the Si oxide, the Zr oxide, the Fe oxide, the Al oxide, the Na compound, the K compound, the fluorine compound, and the Bi oxide described above, is usually 0.5% to 6.0%.
  • the filling rate (the ratio of the total mass of the flux to the total mass of the wire) is not particularly limited. However, from the viewpoint of productivity, the filling rate is preferably 8% to 20% with respect to the total mass of the wire.
  • the diameter of the wire is not particularly limited, but preferably 1.0 mm to 2.0 mm in consideration of convenience during welding.
  • the flux-cored wire 10 according to another aspect of the invention is a flux-cored wire 10 obtained by the method of manufacturing a flux-cored wire 10 according to the embodiment described above.
  • the method of manufacturing a welded joint according to another aspect of the invention is a method of manufacturing a welded joint including a step of welding using the flux-cored wire 10 manufactured by the method of manufacturing a flux-cored wire 10 according to the embodiment described above.
  • the flux-cored wire 10 according to this embodiment contains Cu and Sn, and the Sn content, the Sb content, the W content, and the Mo content satisfy Expression 1. Accordingly, with the flux-cored wire 10 and the method of manufacturing a welded joint according to this embodiment, it is possible to obtain a weld metal having excellent corrosion resistance and mechanical properties in welding of corrosion-resistant steel which is used in an environment which contains corrosive substances such as a high floating salinity environment. In addition, the alloy compositions of the flux-cored wire 10 according to this embodiment are within the above-described predetermined ranges.
  • the flux-cored wire 10 and the method of manufacturing a welded joint of this embodiment together with excellent pit resistance, good welding workability can be obtained such as a small amount of spatters, no cracking during welding, and excellence in the bead shape, bead appearance, and slag delamination, and thus high welding efficiency and an improvement of the quality of a weld part can be achieved.
  • the application of the flux-cored wire 10 and the method of manufacturing a welded joint according to this embodiment is not particularly limited, but it is particularly preferable to apply the flux-cored wire 10 and the method of manufacturing a welded joint to the manufacturing of steel for structure, especially harbor facilities, bridges, building/civil structures, or steel structures such as tanks, ship/marine structures, railways, or containers.
  • the material of the steel to which the flux-cored wire 10 and the method of manufacturing a welded joint according to this embodiment are applied is not particularly limited, and may be normal steel such as carbon steel or low-alloy steel. Anti-weathering steel or low-alloy steel containing Ni, Sn, and the like is more advantageous from the viewpoint of weather resistance and coating corrosion resistance.
  • the form of welding which is performed on the flux-cored wire 10 according to this embodiment and the form of welding which is included in the method of manufacturing a welded joint according to this embodiment are not particularly limited, but gas shield arc welding is preferably performed.
  • gas shield arc welding is preferably performed since no pits are generated, the bead shape, the bead appearance, and the welding workability such as slag delamination are good, and the coating life of a structure including the weld metal is prolonged, horizontal fillet welding is preferably performed.
  • the chemical composition of the flux-cored wire 10 obtained by the method of manufacturing a flux-cored wire 10 according to this embodiment by analysis is because it is not easy to determine whether an element such as Ti, Si, Na, and Ca contained in the flux-cored wire 10 exists in the form of metal or alloy, oxide, fluoride, or carbonate in the flux-cored wire 10.
  • Si metal Si
  • SiO 2 oxide
  • the flux 12 may contain a fluoride, or the fluorine liberated from the flux 12 may damage the analytical instrument.
  • the method of manufacturing a flux-cored wire 10 may include a step of annealing a steel wire with the flux 12 sealed therein, and the annealing may unexpectedly change the composition of the nonmetallic substances of the flux 12.
  • SPCC specified in JIS G 3141: 2011 was used as a steel sheath and filling with a flux was performed. Then, it was reduced in diameter (intermediate annealing for softening of a sheath and for dehydrogenation was performed once) to produce various seamless type flux-cored wires having components shown in Tables 1-1 to 1-4, respectively, with a filling rate of 13.5% and a wire diameter of 1.2 mm without a gap penetrating through the steel sheath. No. 21 was manufactured by caulking.
  • the numerical values in Tables 1-1 to 1-4 are design values, and represent the mass% with respect to the total mass of the flux-cored wire (total mass of the steel sheath and the flux).
  • the test piece was a test piece of a steel type SM490B specified in JIS G 3106: 2008 with a thickness of 12 mm and a length of 600 mm, and a surface of the steel sheet was coated with an inorganic zinc primer to promote the generation of pits such that a thickness of the film was 20 to 25 ⁇ m.
  • the welding conditions were as follows: the welding was performed twice simultaneously at both sides under the welding conditions shown in Table 2, and the bead shape, bead appearance, slag delamination, number of pits, and spatter generation were examined.
  • bead appearance whether bead breakage due to unstable arc, bead necking, and pitting due to voids occurred was determined by visual inspection, and the bead appearance was judged to be “poor” in a case where the bead breakage and the like occurred. The bead appearance was judged to be "good” in a case where the bead breakage and the like did not occur.
  • the slag delamination was judged to be "very good” in a case where the slag was peeled off without impact of a chisel, to be "good” in a case where the slag was peeled off by impact of a chisel (the slag was not peeled off without impact of the chisel), and to be “poor” in a case where the slag remained on the bead even after impact of a chisel.
  • the pit resistance was judged to be "good” in a case where the amount of pits generated was 1 piece/m or less, and to be “poor” in a case where the amount of pits generated was greater than 1 piece/m.
  • Spatters scattering during welding were collected, and the mass of the spatters was measured.
  • the amount of spatters was judged to be "large” in a case where the mass of the spatters per minute was 1.5 g or more, to be “slightly large” in a case where the mass of the spatters per minute was 1.0 to 1.5 g (1.0 g or more and less than 1.5 g), and to be "small” in a case where the mass of the spatters per minute was less than 1.0 g.
  • a deposited metal test was performed according to JIS Z 3111: 2005, and an X-ray inspection was performed. Then, a tensile test, an impact test, and a corrosion resistance evaluation test were performed.
  • the parent material used is a corrosion-resistant steel sheet having a chemical composition containing 0.11% of C, 0.18% of Si, 1.44% of Mn, 0.011 % of P, 0.002% of S, and 0.12% of Sn.
  • the welding conditions are as shown in Table 2.
  • the impact test temperature was 0°C. However, the impact test was performed at 0°C and -40°C for the deposited metal obtained from the wire containing one or more of Ni, Ti, and B.
  • the acceptance criteria for the mechanical properties of the deposited metal a case where the tensile strength was 510 to 660 MPa in the tensile test and the absorbed energy at a test temperature of 0°C was 60 J or more in the impact test was accepted.
  • the deposited metals obtained from the wires (wire Nos. 6 to 16 and 18 to 23) containing one or more of Ti, B, and Ni in order to secure the low temperature toughness a case where the absorbed energy at a test temperature of -40°C was 60 J or more was accepted.
  • the X-ray inspection a case where slag inclusion, blow holes, incomplete penetration, or crater cracking was not observed was accepted.
  • a sample (3 mm thickness ⁇ 60 mm width ⁇ 150 mm length) for producing a corrosion test piece was collected from a position 3 at a depth of 1 mm from a surface of a parent material 1 such that a deposited metal 2 was positioned at a center, and a surface of the sample was subjected to shot blasting. Then, drying by heating was performed at a furnace temperature of 80°C to prepare a corrosion test piece material.
  • any one of a coating A (BANNOH #200 manufactured by Chugoku Marine Paints, Ltd.) and a coating B (NEO GOSEI PRIMER HB manufactured by SHINTO PAINT CO., LTD.) was applied to both surfaces of the corrosion test piece material such that a film on the steel surface had a thickness of 200 to 350 ⁇ m, and thus a corrosion test piece was produced.
  • a cross cut 4 was formed on the corrosion test piece so as to straddle the deposited metal 2, whereby a corrosion test piece 5 in which a coating film damage was simulated was produced.
  • the cross cut 4 was formed by forming scratches reaching from the top of the coating film to the steel surface of the base material by a cutter knife such that the rectangle having the cross cut as a diagonal had a size of 100 mm in long side ⁇ 40 mm in short side. After that, the obtained corrosion test piece 5 was subjected to the evaluation of the corrosion resistance according to the Society of Automotive Engineers (SAE) J2334 test.
  • SAE Society of Automotive Engineers
  • the SAE J2334 test is an acceleration test which is performed in a dry-wet repeating condition having three processes of wet stage (50°C, 100%RH, 6 hours), salt application stage (room temperature, dipping in a saline solution (pH 8, 0.5 mass% of NaCl, 0.1 mass% of CaCl2, and 0.075 mass% of NaHCO 3 ) for 0.25 hours), and dry stage (60°C, 50%RH, 17.75 hours) as one cycle (24 hours in total).
  • the one cycle of the SAE J2334 test is schematically shown in FIG. 3 .
  • a tape delamination rate was obtained by dividing the area of the delamination by the tape delamination operation by the area of the coating film remaining immediately after 80 cycles of the SAE J2334 test. Thereafter, the residual coating film on the surface and the formed rust layer were removed. Corrosion depths of the coating film defect portions were measured, and then an average corrosion depth was calculated.
  • the coating film adhesion evaluation a case where the area ratio of the delamination and swelling was less than 50% and the average corrosion depth of the coating film damage portions was less than 0.50 mm was accepted.
  • the coating film adhesion was judged to be "very good” in a case where the tape delamination rate was 0% to less than 20%, to be “good” in a case where the tape delamination rate was 20% to less than 40%, and to be “poor” in a case where the tape delamination rate was 40% or more.
  • wire Nos. 1 to 23 are invention examples, and wire Nos. 24 to 41 are comparative examples.
  • the TiO 2 equivalent, the SiO 2 equivalent, the ZrO 2 equivalent, the FeO equivalent, the Al 2 O 3 equivalent, the C content, the Si content, the Mn content, the Cu content, the Al content, the Sn content, the Mg content, the sum of the Na 2 O equivalent and the K 2 O equivalent, and the F equivalent were appropriate.
  • the bead shape, the bead appearance, and the slag delamination were not "poor", only a small amount of pits was generated, the amount of spatters was not "large”, there were no defects (crater cracking) in the X-ray inspection, and the tensile strength and the absorbed energy of the deposited metal were also not lower than the acceptance criterion values.
  • the corrosion resistance evaluation test results were also good and not lower than the acceptance criterion values.
  • the content of O excluding O of the compounds such as oxides was 0% to 0.080%, and the content of all O including the compounds such as oxides was 0.5% to 6.0%.
  • the wire Nos. 3 to 5, 12, 13, and 15 to 22 containing an appropriate amount of Bi exhibited very good slag delamination.
  • the absorbed energy of the deposited metal at -40°C was good, that is, 60 J or more.
  • the wire No. 24 had a small TiO 2 equivalent, and thus the amount of slag formed was not sufficient and the bead could not be uniformly enclosed. Thus, the slag was seized and the bead appearance was "poor". The amount of spatters was also large. Furthermore, since the ZrO 2 equivalent was small, the bead shape did not become smooth, a convex bead shape was obtained, and the slag delamination was also "poor".
  • the wire No. 25 had a small TiO 2 equivalent, and thus the slag became thick, pits were generated, the viscosity of the slag increased, and the bead had a swelling toe portion. In addition, since the C content was low, the deposited metal had a low tensile strength and low absorbed energy at 0°C.
  • the wire No. 26 had a large TiO 2 equivalent and a small SiO 2 equivalent, and thus the slag enclosing state deteriorated, and the slag delamination, the bead shape, and the bead appearance were poor.
  • the C content was high, the tensile strength of the deposited metal excessively increased, and thus the ductility decreased. Accordingly, the absorbed energy at 0°C was low.
  • the wire No. 27 had a large SiO 2 equivalent, and thus the amount of spatters increased and pits were also generated. In addition, since the ZrO 2 equivalent was large, a convex bead shape was obtained.
  • the wire No. 28 had a small FeO equivalent, and thus the shape of the bead toe portion was poor.
  • the Si content was low, pits were generated, and the deposited metal had a low tensile strength and low absorbed energy at 0°C.
  • the wire No. 29 had a large FeO equivalent, and thus the slag delamination deteriorated due to a poor slag enclosing state. Accordingly, the bead toe portion swelled, and the bead shape and the bead appearance were also "poor".
  • the Sn content was high, crater cracking occurred.
  • the wire No. 30 had a small Al 2 O 3 equivalent, and thus undercut occurred on the upper leg side and the bead shape was "poor".
  • the Si content was excessively high, the tensile strength of the deposited metal was high, and thus the absorbed energy at 0°C was low due to a decrease in the ductility.
  • the wire No. 31 had a large Al 2 O 3 equivalent, and thus the bead toe portion swelled, the conformability deteriorated, and the bead shape was "poor". In addition, since the Mg content was low, pits were generated.
  • the wire No. 32 has an excessively high Cu content, and the absorbed energy of the deposited metal at 0°C was low. In addition, since the Al content was low, the bead had a convex shape, and undercut occurred in the upper leg portion.
  • the wire No. 33 had a high Al content, and thus the bead shape had no smoothness, the toe portion had a swelling shape, solidification unevenness occurred also in the molten slag, and thus the slag delamination was "poor".
  • the Mg content was high, the amount of spatters increased due to a rough arc.
  • the Mn content was high, the tensile strength of the deposited metal was high, and the absorbed energy at 0°C was low due to a decrease in the ductility.
  • the wire No. 34 had a low Sn content, and thus the area ratio of the delamination and swelling in the deposited metal was large, and the average corrosion depth of the coating film damage portions was also large. In addition, since the Bi equivalent was large, the bead appearance was "poor".
  • the sum of the Na 2 O equivalent and the K 2 O equivalent was large, and thus the amount of spatters was large, the slag delamination, the bead shape, and the bead appearance were "poor".
  • the Mn content was low, pits were generated, and the deposited metal had a low tensile strength and low absorbed energy at 0°C.
  • the wire No. 36 had a low Cu content, and thus the area ratio of the delamination and swelling in the deposited metal was large, and the average corrosion depth of the coating film damage portions was also large. In addition, since the F-equivalent was small, the conformability of the lower leg portion on the lower plate side was poor, the bead shape was "poor", and pits were also generated. Furthermore, since the B content was high, crater cracking occurred.
  • the wire No. 37 had a low Sn content, and thus the area ratio of the delamination and swelling in the deposited metal was large, and the average corrosion depth of the coating film damage portions was also large. In addition, since the F-equivalent was large, the viscosity of the slag decreased, a convex bead shape was obtained, and the slag delamination was also "poor".
  • the wire No. 38 had a low Mg content, and thus pits were generated. In addition, since the Ti content was high, the amount of spatters was large, the slag was seized on the bead surface, and the bead appearance was "poor".
  • the index X was 0 or less, the average corrosion depth immediately under a coating film damage portion of the deposited metal was large, and the coating film adhesion was also "poor".
  • the index X was 0 or less, the area ratio of the delamination and swelling in the deposited metal was large, the average corrosion depth immediately under a coating film damage portion was large, and the coating film adhesion was also "poor".

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  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Nonmetallic Welding Materials (AREA)
EP18912463.9A 2018-03-28 2018-03-28 Method for manufacturing flux-cored wire, flux-cored wire and method for manufacturing welded joint Active EP3753670B1 (en)

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JPS58199693A (ja) * 1982-05-17 1983-11-21 Kobe Steel Ltd フラツクス入りワイヤの製造方法
JP2942787B2 (ja) * 1991-04-11 1999-08-30 日東電工株式会社 複合膜及びそれを用いる液体混合物の分離方法
JP3657127B2 (ja) 1998-09-25 2005-06-08 株式会社神戸製鋼所 ガスシールドアーク溶接用フラックス入りワイヤ
JP2000288781A (ja) 1999-04-09 2000-10-17 Nippon Steel Corp Ｃｕ−Ｎｉ−Ｔｉ系高耐候性鋼用フラックス入りワイヤ
JP2003311471A (ja) 2002-04-19 2003-11-05 Nippon Steel Corp 高Ｎｉ系耐候性鋼のガスシールドアーク溶接用ソリッドワイヤ
JP4259887B2 (ja) 2003-01-31 2009-04-30 株式会社神戸製鋼所 耐食性鋼用ガスシールドアーク溶接用フラックス入りワイヤ
JP4518036B2 (ja) 2006-03-30 2010-08-04 住友金属工業株式会社 石炭・鉱石運搬船ホールド用耐食性鋼材
JP4656054B2 (ja) 2006-12-27 2011-03-23 住友金属工業株式会社 橋梁用鋼材
JP5387192B2 (ja) * 2009-07-16 2014-01-15 新日鐵住金株式会社 ガスシールド溶接用フラックス入りワイヤ
JP5717688B2 (ja) * 2012-04-25 2015-05-13 日鐵住金溶接工業株式会社 原油油槽鋼の水平すみ肉ガスシールドアーク溶接用フラックス入りワイヤ
CN104955610B (zh) * 2013-01-31 2016-09-07 新日铁住金株式会社 药芯焊丝、使用了药芯焊丝的焊接方法、使用了药芯焊丝的焊接接头的制造方法以及焊接接头
WO2015068261A1 (ja) * 2013-11-08 2015-05-14 新日鐵住金株式会社 溶接継手の製造方法
JP6463234B2 (ja) * 2015-08-26 2019-01-30 日鐵住金溶接工業株式会社 原油油槽鋼の２電極水平すみ肉ガスシールドアーク溶接用フラックス入りワイヤ
JP6901868B2 (ja) * 2016-09-13 2021-07-14 株式会社神戸製鋼所 エレクトロスラグ溶接用ワイヤ、エレクトロスラグ溶接用フラックス及び溶接継手
JP6658423B2 (ja) * 2016-09-21 2020-03-04 日本製鉄株式会社 耐食鋼の水平すみ肉ガスシールドアーク溶接用フラックス入りワイヤ

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JPWO2019186797A1 (ja) 2020-04-30
KR102246519B1 (ko) 2021-04-30
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EP3753670A4 (en) 2021-09-08
JP6432715B1 (ja) 2018-12-05

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